Aluminum Sheet Metal Bending Radius

When working with aluminum over sheet metal several variables need to be considered.

Aluminum sheet metal bending radius. Apart from alloy selection thickness and bend radius are also critical factors that must be considered. Steel american iron and steel institute. Per the aluminum association inc. This free chart outlines what bend radii is required for the approximate thickness of aluminum.

The tables below show bend radii and minimum bend sizes for materials and tooling combinations stocked by protocase. Preferred recommended 90 degree bend radii for various sheet metals. In order to develop the flat pattern we add 457 to 1 625 and 2 625 to arrive at 4 707. Say you get a print that says you need to bend a part to an external angle of 100 degrees that s an internal angle of just 80 degrees.

Still if you want to avoid cracking abide by the minimum bend radius in 0 25 in thick 6061 t6 which is quite large see figure 3 and avoid bending acute angles. The table below shows the permitted bend radii for 90 o bending. Since commercial sheet metal bending can be done with less concern for stresses caused during forming operation the radius can be near zero for thin sheet metal. We recommend printing it out to keep as a reference.

Aluminum is typically thicker and stronger and requires more force to bend as well as consideration of edge conditions and punch nose radii. When we calculate the bend allowance we find that it equals 457. Sheet metal bend radii. In our example below a part with flange lengths of 2 and 3 with an inside radius of 250 at 90 will have leg lengths of 1 625 and 2 625 respectively.

It just won t really be at maximum strength. Radii for various thicknesses expressed in terms of thickness t. The bend radius you select may not be available if the geometry of the part will not allow us to bend with the specific tooling required to achieve that radius. Where necessary 5052 h32 may be bent to 1t and 6061 t6 to 1 1 2t.

Aluminum minimum bend radii for 90 degree cold forming of sheet and plate. If you re bending 0 020 thick material use a 0 020 radius. It is possible to choose other bends if you require but additional lead time and tooling charges may apply. The bend radii listed are standard minimum if manufacturing for aircraft and aerospace applications.

Factor 2 thickness and bend radius. We go beyond the general rules of sheet metal bending as our customers want tight bend radii for sheet metal parts. For most applications with stainless steel or aluminum you can get away with a zero radius bend on anything under 0 050 thick.